Tab lock closure for a container

ABSTRACT

A container with a tab lock closure is provided. The container may be constructed from a folded blank of material. The container can consist of a front panel, rear panel, two opposing side panels, and first and second ends. The ends include two opposing minor end flaps and two opposing major end flaps. One major end flap includes a tab that is cut from the flap and is foldably connected to the front panel along a common fold line with the major end flap. The other major end flap includes a corresponding aperture. When the end is closed, the minor end flaps are folded inwardly, the major end flap with the tab is folded inwardly while the tab remains upright, and the other major end flap is then folded inwardly. The tab is then folded inwardly and inserted into the aperture thereby locking the container.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. Provisional Patent ApplicationSer. No. 61/979,593, filed on Apr. 15, 2014, to Phillip Bell, entitled“Push Tab Closure for a Container,” currently pending, the entiredisclosure of which is incorporated herein by reference.

BACKGROUND

Carton and box containers, especially those constructed out ofpaperboard or similar materials, often have tab closure mechanisms forkeeping the ends of the carton or container closed. However, such tabclosure mechanisms generally require intricate and complex endconfigurations in order to effectively lock the container end. Thesecomplex tab closures use several cuts, apertures, protrusions, tabs,notches, etc. in order to create a closure mechanism that effectivelylocks the container. Additionally, tab closure mechanisms typicallyrequire folding of components and extreme bending that causes theclosure mechanism to tear and quickly wear out. Containers with tabclosure mechanisms have also failed to allow for economic and efficientuse of material when the container is formed from a pre-cut blank ofmaterial due to the complex formation of the tab closure mechanisms.

Accordingly, a need exist for a carton or container, particularly onemade from paperboard or like material, that includes a simple anddurable tab locking means for closing the carton or container. A needalso exists for a carton or container with a tab locking means that canbe economically and efficiently constructed from a single unitary blank.

SUMMARY OF THE INVENTION

The objective of the present invention is to provide a carton orcontainer that includes a tab lock closure for locking an end of thecarton or container. A further objective of the present invention is toprovide a tab lock closure that is durable and economically efficient. Afurther object of the present invention is to provide a durable andefficient tab lock closure that simple to lock and unlock. Yet a furtherobjective of the present invention is to provide a carton or containerwith a durable, efficient and simple tab lock closure that can be formedfrom a single unitary foldable blank.

In one embodiment of the present invention, a container is constructedfrom a unitary blank cut from a larger sheet of material. The containermay include a front panel, rear panel, two side panels, an overlappingglue flap panel, and an end construction at both ends of the container.The sidewall panels may be connected by fold lines extending in thelongitudinal direction such that the front panel is adjacent to a sidepanel that is adjacent to the rear panel that is adjacent to anotherside panel. The overlapping glue flap panel may be connected to the sideof one of the wall panels located at either end of the blank. To formthe container, the blank can be folded along the longitudinal fold linesand the overlapping glue flap panel can be adhesively bonded to theopposing exterior wall panel, thereby forming a box-like structure.

One or both ends of the container may include a tab lock closuredesigned to keep the end closed until it is desired to be opened by auser. The end construction of the container may include two opposingminor end flaps, a first major end flap and a second major end flap.Each minor end flap may be foldably connected to the end of one of thecorresponding side panels. The first major end flap may be foldablyconnected to the end of the front panel while the second major end flapmay be foldably connected to the end of the rear panel.

The first major end flap includes a tab that may be cut from the endflap leaving a void space within. The first major end flap and tab mayboth be foldably connected to the front panel. In one embodiment, thefold line connecting the first major end flap to the front panel and thefold line connecting the tab to the front panel are along the same axis,forming a common fold line along the edge of the front panel. The secondmajor end flap can include an aperture defined within that correspondsto the tab of the opposing first major end flap.

In order to close the end construction and use the tab lock closure, thetwo opposing minor end flaps are folded inwards towards the containeropening. The first major end flap may then be folded inwardly towardsthe container opening. The tab may remain in a generally uprightposition when the first major end flap is being closed. The second majorend flap may then be folded inwardly over the first major end flap.Finally, the tab may then be folded down and inserted through theaperture to lock the container. The tab may be slightly bent or bowed inorder to allow the tab to snap underneath the second major end flap tolock the container.

The aperture includes a locking edge that may be positioned such that itis a distance from the tab fold line that is slightly less than theoverall length of the tab. As a result, the tab extends slightly beyondthe locking edge of the aperture when all the end flaps are foldedinward into the closed position and the tab is folded over the aperture.This enables the tab to be snapped past the locking edge of theaperture, positioned underneath part of the second major end flap, andremain in place so as to lock the end construction of the container. Insuch an embodiment, the tab locks in the second major end flap, which inturn locks the first major end flap, which in turn locks the minor endflaps.

Other aspects and advantages of the present invention will be apparentfrom the following detailed description of the preferred embodiments andthe accompanying drawing figures.

DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING

In the accompanying drawing, which forms a part of the specification andis to be read in conjunction therewith in which like reference numeralsare used to indicate like or similar parts in the various views:

FIG. 1 is a top perspective view of a container with an integral tablock closure illustrating one end of the container in an open positionin accordance with a first embodiment of the present invention;

FIG. 2 is a top perspective view of the container of FIG. 1 illustratingone end of the container in a partially closed position where an insideend flap is in a folded orientation;

FIG. 3 is a top perspective view of the container of FIG. 1 illustratingone end of the container in a closed position where both the inside andoutside end flaps are in a folded orientation and the tab lock closureis in an unlocked orientation;

FIG. 4 is a top perspective view of the container of FIG. 1 illustratingone end of the container in a locked position where both the inside andoutside end flaps are in a folded orientation and the tab lock closureis in a locked orientation; and

FIG. 5 is a top plan view of a blank used to form a container having anintegral tab lock closure.

DETAILED DESCRIPTION OF THE INVENTION

The invention will now be described with reference to the drawingfigures, in which like reference numerals refer to like partsthroughout. For purposes of clarity in illustrating the characteristicsof the present invention, proportional relationships of the elementshave not necessarily been maintained in the drawing figures.

The following detailed description of the invention references specificembodiments in which the invention can be practiced. The embodiments areintended to describe aspects of the invention in sufficient detail toenable those skilled in the art to practice the invention. Otherembodiments can be utilized and changes can be made without departingfrom the scope of the present invention. The present invention isdefined by the appended claims and the description is, therefore, not tobe taken in a limiting sense and shall not limit the scope ofequivalents to which such claims are entitled.

Referring to the figures, one embodiment of the present invention isdirected to a carton or container 10 having an integral tab lock closure12 adapted for retaining end flaps of the container 10 in a closed andreleasably locked orientation. It will be appreciated that the tab lockclosure 12 may be suitably implemented with containers and cartonsconfigured, shaped and designed differently than the container 10illustrated in the figures.

The container 10 may be constructed of paperboard, laminated paperboard,cardboard, polymers, thermoplastic materials, molded pulp fiber,laminated molded pulp fiber or any other suitable material now known orhereafter developed. The container 10 may be coated on its interiorand/or exterior surfaces with a waterproof or water-resistant materialsuch as polyethylene, polypropylene or polyester. The container 10 mayalso have designs, labels or other indicia printed or placed thereon.

As illustrated in the figures, the container 10 may include four primarypanels including a front panel 14, rear panel 16, first side panel 18and second side panel 20. The panels 14, 16, 18, and 20 may be foldablyconnected by score lines or panel fold lines 22, 24 and 26, as bestshown in FIG. 5. A glue flap 28 may also be foldably connected to one ofthe panels by a score line or glue flap fold line 30, such as the rearpanel 16 as shown in FIG. 5, according to one embodiment of the presentinvention. The glue flap 28 may be suitable for being adhesively joinedto an adjacent panel when the container 10 is formed, such as the firstside panel 18 as shown in FIG. 5. Several alternative embodiments areenvisioned for the container 10. For example, rather than glue flap 28and glue flap fold line 30, the panels 14, 16, 18, and 20 may beconnected to one another through gusset panels that may be folded toform a box-like container. Several other methods for forming a containerfrom a unitary blank are known to those skilled in the art.

Container 10 may include an end construction 31 at one or both ends ofcontainer 10. End construction 31 may include end flaps 32, 34, 36, and38 connected to panels 14, 16, 18, and 20 as explained in greater detailbelow. The figures illustrate one embodiment where container 10 hasidentical end constructions 31 at both ends; however, in alternativeembodiments, container 10 is designed with an end construction 31 at oneend that is different from the end construction of the other end.

End construction 31 may be constructed in the following manner accordingto one embodiment of the present invention. An opposing pair of firstand second minor end flaps 32 and 34 may be connected to the ends offirst and second side panels 18 and 20, respectively, as best shown inFIG. 5. First and second minor flaps 32 and 34 can be connected to sidepanels 18 and 20 by score lines or end flap fold lines 40 and 42,respectively. Similarly, and opposing pair of first and second opposingmajor end flaps 36 and 38 may be connected to the ends of the front andrear panels 14 and 16, respectively, by score lines or end flap foldlines 44 and 46, respectively, as best shown in FIG. 5. First major endflap 36 includes a distal edge 52 and two opposing side edges 54 and 56.According to the embodiment shown in the figures, distal edge 52 issubstantially parallel to end flap fold line 44 and opposing side edges54 and 56 are substantially perpendicular to distal edge 52. However,distal edge 52 need not be parallel to end flap fold line 44, andopposing side edges 54 and 56 need not be perpendicular to distal edge52. The distal edge 52 and opposing side edges 54 and 56 define theperimeter of the first major end flap 36 along with end flap fold line44. Second major end flap 38 includes a distal edge 58 and two opposingside edges 60 and 62. Similar to first major end flap 36, distal edge 58and opposing side edges 60 and 62 may be constructed with any number ofdifferent orientations and define the perimeter of second major end flap38 along with end flap fold line 46.

Within end construction 31 may be the tab lock closure 12. Again, itwill be understood that the tab lock closure 12 of the present inventioncan be implemented with containers and cartons of designs different fromthat shown in the example provided in the figures.

Tab lock closure 12 may be constructed from at least one tab 48 and atleast one corresponding aperture 50. According to the embodiment shownin the figures, tab lock closure 12 includes one tab 48 and one aperture50. However, in alternative embodiments, tab lock closure 12 can includetwo or more tabs 48 and two or more corresponding apertures 50. The tab48 may be in the form of a tab, tongue ear, projection or other suitablelocking element, while the aperture 50 may be in the form of anaperture, slot, slit, notch or other opening suitable for engagement bytab 48.

Tab 48 may be cut from first major end flap 36 such that first major endflap 36 includes a tab cut line 64 defining the tab 48, as best shown inFIG. 5. In one embodiment of the present invention, tab 48 is cut fromfirst major end flap 36 and remains connected to front panel 14 by ascore line or tab fold line 66. In an alternative embodiment, tab 48 isaffixed to major end flap 36 and/or front panel 14 rather than being cutout of first major end flap 36. Tab fold line 66 and end flap fold line44 may be located along a common axis, as best shown in FIG. 5. In suchan embodiment, tab fold line 66 and flap fold line 44 are generallyaxially coextensive with one another such that both form part of asingle fold line. In an alternative embodiment, tab fold line 66 mayalso be offset from end flap fold line 44. The tab cut line 64 mayextend slightly past fold line 66 in order to create two tab extensioncuts 72. The tab extension cuts 72 may extend slightly into panel 14 andtake the form of a cut, slit, or notch. The tab extension cuts 72facilitate operation of the tab lock closure 12 by allowing slightlateral movement of the tab 48 in a direction represented by arrow 76,as shown in FIG. 4 and further discussed below, when it is moved from alocked orientation to an unlocked orientation.

Tab 48 may include a distal end 70 on its end opposite tab fold line 66,as shown in FIG. 2. The distal end 70 may have a slightly bowed orrounded shape as shown in the figures. Alternatively, distal end 70 maybe in the form of a straight edge. The distal end 70 may also include aprotrusion or other projection in alternative embodiments of the presentinvention.

The second major end flap 38 includes the aperture 50 definedtherethrough, corresponding to tab 48 as explained in greater detailbelow. Aperture 50 can include first and second opposing edges 73 and74, wherein edge 74 may serve as a locking edge, as described herein. Asexplained above, aperture 50 may be in the form of a slot, slit, notchor other similar opening. The aperture 50 need only be wide enough topartially receive tab 48; however, aperture 50 may have a width widerthan that of tab 48. A peripheral shape of the locking edge 74 maygenerally correspond to a peripheral shape of the distal edge 70 of tab48 in order to better facilitate engagement between locking edge 74 anddistal edge 70 when locking the tab closure 12.

As shown in FIG. 1, when end construction 31 of container 10 is beingclosed, the minor flaps 32 and 34 are first folded inwardly. However, insome embodiments of the present invention, container 10 in constructedwithout minor end flaps 32 and 34. As depicted in FIG. 2, the firstmajor end flap 36 may be folded inwardly into a folded orientation overthe minor end flaps 32 and 34. The tab 48 may remain in a generallyupright and unlocked orientation when first major end flap 36 placed inthe folded orientation. If tab 48 is cut from the first major end flap36, a resulting tab void 68 with a void edge 69 is defined in the firstmajor end flap 36. In an alternative embodiment, where tab 48 isattached to first major end flap 36 rather than cut out from first majorend flap 36, an overlapping zone with an overlapping zone edge serves asan equivalent to the void 68 and the void edge 69.

As illustrated in FIG. 3, after the minor end flaps 32 and 34 and thefirst major end flap 36 are all placed in the folded orientation, thesecond major end flap 38 can then be folded inwardly into a foldedorientation to a position overlying the first major end flap 36. Afterall of the end flaps 32, 34, 36, and 38 have been placed into the foldedorientation, the end construction 31 of container 10 is in a closedorientation. In one embodiment, second major end flap 38 has a lengthfrom its end flap fold line 46 to its edge 58 that is substantially thesame distance between front panel 14 and rear panel 16. In such anembodiment, second major end flap 38 substantially overlaps first majorend flap 36 when both are folded inward into their respective foldedorientations. As also illustrated in FIG. 3, the tab 48 may remaingenerally upright and in its unlocked orientation when second major endflap 38 is folded inward and over first major end flap 36.

As explained above, tab 48 can project from tab fold line 66 and has adistal end 70. As illustrated in FIG. 3, tab 48 has a length D₁, whichis the distance between the tab fold line 66 and distal end 70. Thelength of tab 48, or D₁, corresponds to the length of the tab void 68,which is the distance between tab fold line 66 and void edge 69. Whenthe second major end flap 38 is folded inwardly into the foldedorientation, the aperture 50 defined therein generally overlies the void68 defined in the first major end flap 36. The aperture 50 may be of anysuitable size and shape, and in one embodiment, has a size and shapegenerally similar to that of the void 68 resulting from tab 48. Asdemonstrated in FIG. 3, aperture 50 may be positioned within secondmajor end flap 38 such that a distance D₂ is defined between the tabfold line 66 and aperture locking edge 74 when second major end flap 38is placed into a folded orientation. Distance D₂ may be slightly lessthan distance D₁. As a result, the locking edge 74 of aperture 50 mayslightly overlap the void edge 69 when both first major end flap 36 andsecond major end flap 38 are placed their folded orientations.

In order to place end construction 31 of the container 10 into a lockedposition, a user may fold or rotate the tab 48 from an unlockedorientation downward toward the aperture 50, as represented by arrow 82in FIG. 3, and push the tab 48 through the aperture 50, as shown in FIG.4, placing the tab 48 into the locked orientation and the endconstruction 31 into a locked position. The distal end 70 of the tab 48becomes snappingly engaged or tucked underneath the locking edge 74 ofthe aperture 50. When the length D₁ of the tab 48 is slightly greaterthan the distance D₂ defined between the tab's fold line 66 and theaperture locking edge 74, engagement between the locking edge 74 and thetab's distal end 70 occurs. This engagement holds and locks the tab 48underneath second major end flap 38 and locking edge 74. When the tab 48is pushed into the aperture 50 to create a locking engagement, eitherone or both of the tab 48 and second major end panel 38 may becomemomentarily slightly bowed or deformed inwardly in order to allow thedistal end 70 of the tab 48 to pass by the locking edge 74 of theaperture 50. Once the user releases pressure from the tab 48, the tab 48and second major end panel 38 may return to their original shape suchthat the distal end 70 of the tab 48 is retained underneath the lockingedge 74 of the aperture 50. In one embodiment, the tab 48 acts as astrap overlying at least a portion 84 of the second major end flap 38 tohold the flap 38 in a folded orientation. The second major end flap 38in turn holds the first major end flap 36 in a folded orientation, whichin turn holds the minor end flaps 32 and 34 in a folded orientation.

When a user desires to open the container 10, the user disengages thetab 48 from the aperture 50. To do this, the user may place the pad of afinger or thumb on the tab 48 and slide or deflect the tab 48 in adirection represented by arrow 76 (see FIG. 4), for example laterallyoutwardly, in order to disengage the tab's distal end 70 from theaperture's locking edge 74. As best depicted in FIG. 5, tab extensioncuts 72 of the tab cut line 64 forming the tab 48 may extend beyond thetab's fold line 66 into the front panel 14 in order to facilitate thetab 48 being slid in the direction of arrow 76. Alternatively, the usermay place a finger nail, or suitable alternative, under the tab 48 todeflect the tab 48 away from the second major end flap 38, asrepresented by arrow 78 (see FIG. 4), in order to disengage the tab'sdistal end 70 from the aperture's locking edge 74.

As shown in FIG. 5, the carton 10 can be constructed from a flat blank80 of material that may be formed of paperboard or other suitablematerial as described above. A plurality of blanks 80 may be cut (e.g.,die cut) from a larger sheet or roll of material. The tab cut line 64and extension cuts 72 forming the tab 48 and the cut forming theaperture 50 may be simultaneous made at the time the blank 80 is cutfrom the sheet or roll of material.

From the foregoing, it will be seen that this invention is one welladapted to attain all the ends and objects hereinabove set forthtogether with other advantages which are obvious and which are inherentto the structure. It will be understood that certain features and subcombinations are of utility and may be employed without reference toother features and sub combinations. This is contemplated by and iswithin the scope of the claims. Since many possible embodiments of theinvention may be made without departing from the scope thereof, it isalso to be understood that all matters herein set forth or shown in theaccompanying drawings are to be interpreted as illustrative and notlimiting.

The constructions described above and illustrated in the drawings arepresented by way of example only and are not intended to limit theconcepts and principles of the present invention. Thus, there has beenshown and described several embodiments of a novel invention. As isevident from the foregoing description, certain aspects of the presentinvention are not limited by the particular details of the examplesillustrated herein, and it is therefore contemplated that othermodifications and applications, or equivalents thereof, will occur tothose skilled in the art. The terms “having” and “including” and similarterms as used in the foregoing specification are used in the sense of“optional” or “may include” and not as “required”. Many changes,modifications, variations and other uses and applications of the presentconstruction will, however, become apparent to those skilled in the artafter considering the specification and the accompanying drawings. Allsuch changes, modifications, variations and other uses and applicationswhich do not depart from the spirit and scope of the invention aredeemed to be covered by the invention which is limited only by theclaims which follow.

What is claimed is:
 1. A container with a tab lock closure, thecontainer comprising: a first end flap foldably connected to a firstsidewall panel by a first fold line; a second end flap foldablyconnected to a second sidewall panel by a second fold line; a tab cutfrom the first end flap, the tab being foldably connected to the firstsidewall panel by a tab fold line and having a distal end, wherein thetab fold line is generally axially coextensive with the first fold line;and an aperture defined in the second end flap, the aperture having alocking edge suitable for engagement by the distal end of the tab. 2.The container of claim 1, wherein when the container is in a closedposition, the first end flap is folded inward into a folded orientationand the second end flap is folded inward into a folded orientationoverlying the first end flap.
 3. The container of claim 2, wherein whenthe container is in a locked position, the tab at least partiallyoverlies the second end flap and the tab distal end is at leastpartially underneath the locking edge of the aperture.
 4. The containerof claim 3, wherein a first distance is defined between the tab distalend and the tab fold line and a second distance is defined between thelocking edge of the aperture and the tab fold line when the container isin the closed position, and wherein the first distance is slightlygreater than the second distance so that the tab distal end engages andis retained underneath the locking edge of the aperture when thecontainer in placed in the locked position from the unlocked position.5. The container of claim 3, wherein a cut forming the tab extendsbeyond the tab fold line and into the first sidewall panel a distancesuitable for allowing the tab to be moved laterally to disengaged thetab distal end from the locking edge of the aperture when the containeris in the locked position.
 6. The container of claim 1, wherein the tabis defined completely within a perimeter of the first end flap.
 7. Thecontainer of claim 1, wherein the tab is located at least partiallywithin the first sidewall panel and at least partially within the firstmajor end flap.
 8. The container of claim 1, wherein a peripheral shapeof the distal end of the tab substantially corresponds to a peripheralshape of the locking edge of the aperture.
 9. A container with a tablock closure, the container comprising: a first end flap connected to afront panel by a first fold line, the first end flap adapted for foldinginwardly to a folded orientation; a second end flap connected to a rearpanel by a second fold line, the second end flap adapted for foldinginwardly to a folded orientation; a tab at least partially cut out ofand at least partially defined within the first end flap, the tab havinga distal end; and an aperture defined in the second end flap, theaperture having a locking edge adapted for engaging with and at leastpartially overlapping the distal end of the tab; wherein when both ofthe first end flap and the second end flap are in their respectivefolded orientations, the second end flap substantially overlaps thefirst end flap and the container is in a closed position.
 10. Thecontainer of claim 9, wherein the tab at least partially overlies aportion of the second end flap and the tab distal end is at leastpartially underneath the locking edge of the aperture when the containeris in a locked position.
 11. The container of claim 10, wherein the tabis connected to the front panel by a tab fold line.
 12. The container ofclaim 11, wherein a first distance is defined between the tab distal endand the tab fold line and a second distance is defined between thelocking edge of the aperture and the tab fold line when the first andsecond end flaps are in their respective folded orientations, andwherein the first distance is slightly greater than the second distanceso that the tab distal end engages and is retained underneath thelocking edge of the aperture when the container is placed in the lockedposition.
 13. The container in claim 11, wherein a cut forming the tabextends beyond tab fold line a distance suitable for allowing the tab tobe moved laterally to disengage the tab distal end from the locking edgeof the aperture when the container is in the locked position.
 14. Thecontainer in claim 11, wherein the tab fold line and the first fold lineare generally axially coextensive with one another.
 15. A foldable blankfor forming a container, the blank comprising: a front panel; a rearpanel; a first end flap connected to the front panel by a first foldline; a second end flap connected to the rear panel by a second foldline; a tab cut from the first panel and connected to the front panel bya tab fold line, the tab having a distal end opposite the tab fold line;and an aperture defined within the second end flap, the aperture havinga locking edge; wherein when the blank is formed into the container, thesecond end flap is adopted to substantially overly the first end flapwhen the container is in a closed position, and wherein the tab foldline and the first fold line form a common fold line.
 16. The blank ofclaim 15, wherein when the blank is formed into the container, a firstdistance is defined between the tab distal end and the tab fold line anda second distance is defined between the locking edge of the apertureand the tab fold line when the container is in the closed position, andwherein the first distance is slightly greater than the second distanceso that the tab distal end may engage the locking edge of the aperture.17. The blank of claim 15, wherein the first end flap includes a tabvoid corresponding to the shape of the tab.
 18. The blank of claim 17,wherein the tab void is defined within a perimeter of the first endflap.